Miniature brake and method of assembly

ABSTRACT

A brake and method of assembly are provided. The brake includes a friction plate configured for coupling to a rotatable body for rotation with the rotatable body about an axis of rotation, a pressure plate disposed about the axis on a first side of the friction plate and fixed against rotation, and an armature plate disposed about the axis on a second side of the friction plate. An electromagnet is disposed about the axis on an opposite side of the armature plate relative to the friction plate. A spring biases the armature plate in a first axial direction towards the friction plate and away from the electromagnet to engage the brake. A fastener couples the pressure plate to the electromagnet. The fastener conforms to a space between opposed surfaces of the pressure plate and the electromagnet and, upon hardening, bonds the pressure plate to the electromagnet.

BACKGROUND OF THE INVENTION a. Field of the Invention

This disclosure relates to an electromagnetic brake. In particular, theinstant disclosure relates to an electromagnetic brake in whichcomponents are joined without the use of conventional fasteners tofacilitate manufacture of a relatively small brake that is capable ofgenerating a relatively high level of braking torque.

b. Background Art

In conventional electromagnetic brakes, brake components are coupledtogether using threaded fasteners, bolts, pins, swaging and/or pressfits. Certain applications, however, require brakes that are relativelysmall and conventional fasteners often limit how small the brake can bemade. In particular, conventional fasteners generally must remain largeenough to enable easy handling and assembly of the brake. Further, thespace in the brake required by conventional fasteners limits thepotential size of the electromagnetic components of the brake and,therefore, the brake torque that can be generated.

The inventors herein has recognized a need for a brake that willminimize and/or eliminate one or more of the above-identifieddeficiencies.

BRIEF SUMMARY OF THE INVENTION

A brake and a method of assembling a brake are described herein. Thebrake is assembled without the use of conventional fasteners tofacilitate manufacture of a relatively small brake that is capable ofgenerating a relatively high level of braking torque.

A brake in accordance with one embodiment of the invention includes afriction plate configured for coupling to a rotatable body for rotationwith the rotatable body about an axis of rotation. The brake furtherincludes a pressure plate disposed about the axis on a first side of thefriction plate and fixed against rotation and an armature plate disposedabout the axis on a second side of the friction plate. The brake furtherincludes an electromagnet disposed about the axis on an opposite side ofthe armature plate relative to the friction plate. The brake furtherincludes a spring biasing the armature plate in a first axial directiontowards the friction plate and away from the electromagnet to engage thebrake. The brake further includes a fastener coupling the pressure plateto the electromagnet. The fastener conforms to a space between opposedsurfaces of the pressure plate and the electromagnet and, uponhardening, bonds the pressure plate to the electromagnet.

A method of assembling brake in accordance with one embodiment of theinvention includes the step of arranging a friction plate, a pressureplate, an armature plate and a first member of an electromagnet suchthat the friction plate is disposed about an axis of rotation, thepressure plate and armature plate are disposed about the axis onopposites sides of the friction plate, the first member of theelectromagnet is disposed about the axis on an opposite side of thearmature plate from the friction plate, and the pressure plate isaligned with the first member of the electromagnet to define a spacebetween opposed surfaces of the pressure plate and the first member ofthe electromagnet. The method further includes the step of coupling thepressure plate to the first member of the electromagnet with a fastener.The fastener conforms to the space between the opposed surfaces of thepressure plate and the first member of the electromagnet and, uponhardening, bonds the pressure plate to the first member of theelectromagnet. The method further includes the steps of inserting aspring into the first member of the electromagnet and coupling a secondmember of the electromagnet supporting a conductor to the first memberof the electromagnet such that the conductor is disposed radiallybetween the first and second members of the electromagnet and the springextends through the first member of the electromagnet and is seatedbetween the armature plate and the second member of the electromagnet.

A brake and method of assembling a brake in accordance with the presentteachings are advantageous relative to conventional brakes and methodsof assembly. In particular, the brake described herein is made withoutthe use of conventional fasteners. As a result, the brake can be maderelatively small while retaining sufficient size for electromagneticcomponents of the brake in order to generate a relatively high level oftorque. The elimination of conventional fasteners also enables moreefficient assembly of the brake and prevents contamination of frictionsurfaces in the brake with thread locking adhesives that are often usedwith conventional fasteners. The brake described herein also enables aprecise air gap between the armature plate and electromagnet to beestablished during assembly by removing the impact of a tolerancestackup of the brake components.

The foregoing and other aspects, features, details, utilities, andadvantages of the invention will be apparent from reading the followingdetailed description and claims, and from reviewing the accompanyingdrawings illustrating features of this invention by way of example.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-2 are exploded perspective views of a brake in accordance withone embodiment of the present invention.

FIGS. 3-4 are cross-sectional views of the brake of FIGS. 1-2 .

FIG. 5 is an enlarged exploded view illustrating the relationshipbetween certain components of the brake of FIGS. 1-2 .

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein like reference numerals are usedto identify identical components in the various views, FIG. 1-4illustrate a brake 10 in accordance with one embodiment of theinvention. Brake 10 provides a braking torque to a rotatable body suchas a shaft, gear, pulley, blade, etc. in order to slow or halt rotationof a rotating body or to prevent rotation of a stationary body (i.e., aparking brake). It will be understood by those of ordinary skill in theart that brake 10 may be used in a wide variety of industrial and otherapplications requiring a brake. Brake 10 may include a friction plate12, a pressure plate 14, an armature plate 16, means, such as springs18, for biasing armature plate 16 in one direction, and means, such aselectromagnet 20, for urging armature plate 16 in another direction.Referring to FIG. 3 , in accordance with one aspect of the presentteachings, brake 10 may also include one or more fasteners 22 used tocouple the pressure plate 14 and electromagnet 20 together.

Friction plate 12 is provided to transmit a braking torque to a shaft orother rotating body. Friction plate 12 may be made from conventionalmetals or plastics and may be made by stamping, molding and/ormachining. Friction plate 12 may be annular in shape and disposed about,and centered about, a rotational axis 24. Referring to FIGS. 3-4 , inthe illustrated embodiment the outer diameter of friction plate 12varies along the axial length of friction plate 12 such that a smallerdiameter portion 26 is disposed within, and radially aligned with, aportion of pressure plate 14 while a larger diameter portion 28 isdisposed axially between pressure plate 14 and armature plate 16.Friction plate 12 is coupled to, and configured for rotation with, ashaft (not shown) or other rotating body about axis 24. Friction plate12 may be rotationally coupled to the shaft in a variety of ways thatpermit axial movement of friction plate 12 relative to the shaft toenable proper operation of brake 10 and account for wear, vibration,runout or thermal expansion. For example, the radially inner surface offriction plate 12 and the radially outer surface of the shaft may havecomplementary, torque transmitting, shapes such as splines, a key andkeyway, single or double D-shape or hexagonal shape. Friction plate 12includes friction surfaces on opposed sides 30, 32 configured to engagepressure plate 14 and armature plate 16, respectively, during engagementof brake 10.

Referring again to FIGS. 1-2 , pressure plate 14 is configured to engagefriction plate 12 during application of brake 10 to transmit a brakingtorque to friction plate 12. Pressure plate 14 provides a reactionsurface against which armature plate 16 presses friction plate 12 duringapplication of brake 10. In accordance with one aspect of the presentteachings, pressure plate 14 also establishes the relative positions andorientations of components of brake 10 and inhibits relative rotation ofthose components about axis 24. Pressure plate 14 may be made fromconventional metals, plastics or composites. Pressure plate 14 includesan annular body 34 and a plurality of arms 36 extending from body 34.Body 34 and arms 36 may together form a unitary (one-piece) structurewhich may be fixed against rotation by coupling pressure plate 14 to arotationally fixed structure such as electromagnet 20. Referring to FIG.3 , body 34 is disposed on side 30 of friction plate 12 and may bedisposed about, and centered about, axis 24. Body 34 provides a reactionsurface configured to engage friction plate 12 during application ofbrake 10. Referring again to FIGS. 1-2 , arms 36 position and orientpressure plate 14 relative to the other components of brake 10 andprevent relative movement between the components. The combination ofbody 34 and arms 36 enables a single component to function as a reactionsurface, establish the axial and circumferential positions of thecomponents of brake 10 and prevent relative rotation of components inbrake 10 thereby simplifying the design and assembly of brake 10. Arms36 extend axially from body 34 and, in particular, from a radially outerportion of body 34 such that body 34 and arms 36 establish a constantouter diameter of pressure plate 14. In the illustrated embodiment,pressure plate 14 includes three arms 36. It should be understood,however, that the number of arms 36 may vary. In the illustratedembodiments, arms 36 are equally, circumferentially spaced about axis24. It should be understood, however, that the spacing between arms 36may vary. Each arm 36 is substantially rectangular in shape when viewedin a radial direction. Referring to FIG. 5 , each arm 36 defines aplurality of walls 38, 40, 42 extending between radially inner and outersurfaces 44, 46 of arm 36. Wall 38 extends in a generallycircumferential direction and is disposed at one axial end of arm 36distant from body 34. Walls 40, 42 extend in a generally axial directionbetween body 34 and wall 38. In the illustrated embodiment, each arm 36further defines an aperture 48 that extends radially through arm 32between surfaces 44, 46 of arm 36 for a purpose described hereinbelow.

Referring again to FIGS. 1-2 , armature plate 16 is configured to engagefriction plate 12 during application of brake 10 to transmit a brakingtorque to friction plate 12. Armature plate 16 may be made from metalsor metal alloys or other materials having relatively low magneticreluctance such as iron or steel. Referring to FIG. 3 , armature plate16 is disposed on side 32 of friction plate 12. Armature plate 16 isannular in shape and may be disposed about, and centered about, axis 24.Armature plate 16 is axially movable towards and away from frictionplate 12 and pressure plate 14 to permit engagement and disengagement ofbrake 10. Referring again to FIGS. 1-2 , armature plate 16 is fixedagainst rotation about axis 24. In particular, armature plate 16 definesa plurality of slots 50 in a radially outer perimeter configured toreceive arms 36 of pressure plate 14. Upon assembly, arms 36 of pressureplate 14 extend through slots 50 in armature plate 16 such that walls40, 42 of each arm 36 are circumferentially aligned with correspondingwalls in armature plate 16 forming a corresponding slot 50 therebyinhibiting relative rotation of pressure plate 14 and armature plate 16.

Springs 18 provide a means for biasing armature plate 16 in onedirection along axis 24 towards friction plate 12 and pressure plate 14and away from electromagnet 20 to engage brake 10. Springs 18 are seatedbetween armature plate 16 and a surface of electromagnet 20 and exert abiasing force on armature plate 16 urging friction plate 12 towardspressure plate 14. Springs 18 are disposed in an annular array aboutaxis 24 and may be equally circumferentially spaced about axis 24.

Electromagnet 20 provides a means for urging armature plate 16 in theopposite direction along axis 24 away from friction plate 12 andpressure plate 14 to disengage brake 10. Electromagnet 20 also providesstructural support and orients other components of brake 10 includingpressure plate 14 and springs 18. Electromagnet 20 is disposed on a sideof armature plate 16 opposite friction plate 12 and includes inner andouter members 52, 54 and a conductor 56 which may comprise aconventional wound coil or similar conductor. Energizing the conductorcreates an electromagnetic circuit among armature plate 16, members 52,54 and conductor 56 that urges armature plate 16 towards electromagnet20 and away from friction plate 12 against the biasing force of springs18 to disengage brake 10. Members 52, 54 may be made from metals ormetal alloys or other materials having relatively low magneticreluctance such as iron or steel.

Referring to FIGS. 3-4 , inner member 52 supports conductor 56 andprovides a seat for springs 18 in addition to functioning as part of theelectromagnetic circuit. Inner member 52 is generally annular in shapeand may be disposed about, and centered about, axis 24. Inner member 52has an outer diameter that varies along the axial length of member 52. Asmaller diameter portion 58 of member 52 is disposed proximate one axialend of member 52 proximate armature plate 16 and is sized to supportconductor 56 and outer member 54 thereon. A larger diameter portion 60of member 52 is disposed proximate the opposite axial end of member 52distant from armature plate 16. Referring to FIG. 4 , portion 60 definesa radially extending surface 62 that functions as a spring seat for eachspring 18. An annular, axially extending flange 64 extends from aradially outer surface of portion 60 in the direction of armature plate16 and is configured to engage outer member 54 in a press fitrelationship.

Outer member 54 provides a means for coupling electromagnet 20 topressure plate 14 in addition to functioning as part of theelectromagnetic circuit. Outer member 54 is annular in shape and may bedisposed about, and centered about, axis 24. Outer member 54 defines aplurality of bores extending from one axial end of member 54 to anopposite end of member 54 and configured to receive springs 18 such thatsprings 18 are located radially outwardly of conductor 56. Referring toFIG. 3 , outer member 54 has an outer diameter that varies along theaxial length of member 54. A small diameter portion 66 of member 54 isdisposed proximate one axial end of member 54 distant from armatureplate 16 and is configured to engage flange 64 of member 52 in a pressfit relationship. A larger diameter portion 68 of member 54 is disposedproximate the axial end of member 54 near armature plate 16 and has anouter diameter equal to the outer diameter of portion of 60 of member52. Portions 66, 68 define a shoulder therebetween configured to engageflange 64 to position members 52, 54 relative to one another. Referringto FIG. 1 , portion 68 of member 54 defines a plurality of recesses 70in a radially outer surface that are axially aligned with slots 50 inarmature plate 16 and are configured to receive arms 36 of pressureplate 14. The shapes of arms 36 and recesses 70 are complementary. Inparticular, each recess 70 is substantially rectangular in shape whenviewed in a radial direction. Referring to FIG. 5 , each recess 70 isdefined by a floor 72 configured to engage radially inner surface 44 ofarm 36 and a plurality of walls 74, 76, 78 extending radially from thefloor 72 to a radially outermost surface of member 54. Wall 74 extendsin a generally circumferential direction and is disposed at one axialend of recess 70. Walls 76, 78 extend in a generally axial directionbetween wall 74 and one axial end of member 54. Walls 74, 76, 78 areconfigured to engage walls 38, 40, 42, respectively, of arm 36 uponassembly. Walls 40, 42 of arms 36 and walls 76, 78 in member 54 inhibitrelative rotation of pressure plate 14 and electromagnet 20 uponassembly. In the illustrated embodiment, member 54 further defines awell 80 formed in the floor 72 of each recess 70. Well 80 is configuredfor radial alignment with aperture 48 in arm 36 upon assembly of brake10. Referring to FIG. 3 , at least one of an axial dimension of well 80and a circumferential dimension of well 80 is greater than acorresponding axial or circumferential dimension of aperture 48 for apurpose described below.

Fasteners 22 are provided to couple pressure plate 14 to electromagnet20. In accordance with one embodiment, fasteners 22 are made frompolymers and, in particular, thermosetting polymers including plastics,polyesters, epoxies, polyimides, polyurethanes, silicones or melamineresins that flow freely into a space between opposed surfaces of thepressure plate 14 and electromagnet 20, conform to the space and, uponhardening, bond pressure plate 14 to electromagnet 20. In accordancewith another embodiment fasteners 22 comprise welds formed fromresistance welding (and, in particular, spot welding) in which heat isgenerated at the interfaces between arms 36 and electromagnet 20 bypassing electric current through pressure plate 14 and electromagnet 20under pressure in order to join faying surfaces of the arms 36 andelectromagnet 20. The welds likewise conform to the space betweenopposed surfaces of the pressure plate and the electromagnet and, uponhardening, bond the pressure plate 14 to the electromagnet 20. In thisembodiment, apertures 48 in arms 36 and wells 80 in member 54 ofelectromagnet 20 may be eliminated. By using these fasteners (i.e.,polymer materials and/or welds) to couple pressure plate 14 andelectromagnet 20, brake 10 can be formed without the use of conventionalfasteners such as screws, bolts, pins, etc. During assembly of theembodiment of brake 10 employing polymer fasteners, arms 36 of pressureplate 14 are inserted into recesses 70 in member 54 of electromagnet 20such that the aperture 48 in each arm 36 is radially aligned with acorresponding well 80 in member 54. The polymer material is extrudedthrough aperture 48 and into well 80 and conforms to the shape ofaperture 48 and well 80 and the space between pressure plate 14 andelectromagnet 20. Referring to FIG. 3 , because at least one of theaxial and circumferential dimensions of well 80 is greater than thecorresponding axial and circumferential dimensions of aperture 48, thematerial fills the space between a radially inner surface of pressureplate 14 (in particular, surface 44 of arm 36 (see FIG. 5 ) and aradially outer surface of electromagnet 20 (in particular, floor 72 ofrecess 70 of member 54 (see FIG. 5 )) and bonds to the radially innersurface of pressure plate 14 and the radially outer surface ofelectromagnet 20.

Referring again to FIGS. 1-2 , brake 10 may be assembled in accordancewith the following method. The method may begin with the step ofarranging friction plate 12, pressure plate 14, armature plate 16 andmember 54 of electromagnet 20 such that friction plate 12 is disposedabout axis 24, pressure plate 14 and armature plate 16 are disposedabout axis 24 on opposites sides of friction plate 12, member 54 ofelectromagnet 20 is disposed about axis 24 on an opposite side ofarmature plate 16 relative to friction plate 12, and pressure plate 14is aligned with member 54 of electromagnet 20 to define a space betweenopposed surfaces in pressure plate 14 and member 54 of electromagnet 20.This step may include the substep of moving pressure plate 14 and/orarmature plate 16 and inserting arms 36 of pressure plate 14 throughslots 50 in armature plate 16. This step may further include the substepof moving pressure plate 14 and/or member 54 of electromagnet 20 andinserting arms 36 of pressure plate 14 into recesses 70 in member 54. Inthe embodiment in which polymer fasteners are used, arms 36 preferablyextend far enough into recesses 70 to radially align apertures 48 inarms 36 with corresponding wells 80 in member 54. The method maycontinue with the step of establishing a predetermined distance betweenarmature plate 16 and the member 54 of electromagnet 20. This step mayinclude the substep of inserting a shim having a known thickness betweenarmature plate 16 and member 54 of electromagnet 20. In this manner, theair gap between armature plate 16 and member 54 is set to apredetermined distance as opposed being dependent on the tolerancestackup during assembly. The method may continue with the step ofcoupling pressure plate 16 to member 54 of electromagnet 20 with one ofmore fasteners 22. This step may include the substep of inserting amaterial, such as a thermosetting polymer, into the aperture 48 in eacharm 36 of pressure plate 14 and into the corresponding well 80 in eachrecess 70 in member 54. The material will conform to the spaces betweenopposed surfaces in pressure plate 14 and member 54 (e.g., between theradially inner surface 44 of arm 36 and floor 72 of recess 70 of member54 (see FIG. 5 )) and, upon hardening, bond pressure plate 14 to member54. Alternatively, this step may include the substeps of applyingpressure to the interfaces between arms 36 of pressure plate 14 andelectromagnet 20 and generating heat at the interface (i.e., resistancewelding) to create fasteners in the form of welds between the opposedsurfaces of the arms 36 and electromagnet 20. The welds will likewiseconform to the spaces between the opposed surfaces in pressure plate 14and member 54 of electromagnet 20 (e.g., between the radially innersurface 44 of arm 36 and floor 72 of recess 70 of member 54 (see FIG. 5)) and, upon hardening, bond pressure plate 14 to member 54. The methodmay continue with the step of inserting springs 18 into member 54 ofelectromagnet 20. The method may then continue with the step of couplingmember 52 of electromagnet 24 supporting conductor 56 to member 54 ofelectromagnet 20. Once coupled, conductor 56 will be disposed radiallybetween members 52, 54 and springs 18 will be seated between armatureplate 16 and member 52 of electromagnet 20 (in particular, surface 62 ofmember 52).

A brake 10 and method of assembling a brake in accordance with thepresent teachings are advantageous relative to conventional brakes andmethods of assembly. In particular, the brake 10 described herein ismade without the use of conventional fasteners. As a result, the brake10 can be made relatively small while retaining sufficient size forelectromagnetic components of the brake 10 in order to generate arelatively high level of torque. The elimination of conventionalfasteners also enables more efficient assembly of the brake 10 andprevents contamination of friction surfaces in the brake 10 with threadlocking adhesives that are often used with conventional fasteners. Thebrake 10 described herein also enables a precise air gap between thearmature plate 16 and electromagnet 20 to be established during assemblyby removing the impact of a tolerance stackup of the brake components.

While the invention has been shown and described with reference to oneor more particular embodiments thereof, it will be understood by thoseof skill in the art that various changes and modifications can be madewithout departing from the spirit and scope of the invention.

What is claimed is:
 1. A method of assembling a brake, comprising thesteps of: coupling a first member of an electromagnet to a second memberof the electromagnet supporting a conductor such that the conductor isdisposed radially between the first and second member of theelectromagnet; inserting a spring into the electromagnet; arranging anarmature plate, a friction plate, a pressure plate, and theelectromagnet such that the friction plate is disposed about an axis ofrotation, the pressure plate and armature plate are disposed about theaxis on opposites sides of the friction plate, the electromagnet isdisposed about the axis on an opposite side of the armature plate fromthe friction plate and the spring is seated between the armature plateand the second member of the electromagnet, and the pressure plate isaligned with the first member of the electromagnet to define a firstspace between opposed surfaces of the pressure plate and the firstmember of the electromagnet; and coupling the pressure plate to thefirst member of the electromagnet with a first fastener, the firstfastener conforming to the first space between the opposed surfaces ofthe pressure plate and the first member of the electromagnet and, uponhardening, bonding the pressure plate to the first member of theelectromagnet.
 2. The method of claim 1 wherein the first fastenercomprises a weld.
 3. The method of claim 1 wherein the step of couplingthe pressure plate to the first member of the electromagnet includesapplying pressure to an interface between the pressure plate and thefirst member of the electromagnet including the first space andgenerating heat at the interface.
 4. The method of claim 1, furthercomprising the step of coupling the pressure plate to the first memberof the electromagnet with a second fastener, the second fastenerconforming to a second space between the opposed surfaces of thepressure plate and the first member of the electromagnet and, uponhardening, bonding the pressure plate to the first member of theelectromagnet.